Evaluation of oxy-acetylene flame angle effect on the erosion resistance of SiC/ZrB2–SiC/ZrB2 multilayer coatings fabricated by the shielding shrouded plasma spray technique

Abstract

In the present study, the effect of oxy-acetylene flame angle on the erosion resistance of SiC/ZrB2–SiC/ZrB2 multilayer coatings with the gradient structure was investigated. To this aim, first, the SiC inner layer was applied by the reactive melt infiltration (RMI) technique; then ZrB2 and ZrB2–SiC layers with 10, 20 and 30%wt. SiC were applied on graphite by the plasma spraying technique. To prevent the oxidation of ZrB2 and SiC particles, the plasma spraying process was performed by a solid protective shield. To evaluate the performance of the coatings in erosive environments, the samples were exposed to oxy-acetylene flame at the angles of 30°, 60° and 90° for 360 s; the destruction mechanism of SiC/ZrB2–SiC/ZrB2 multilayer coatings appeared to be controlled mechanically and chemically. The results of the erosion test showed that at the low flame angles of about 30°, due to the shear forces of oxy-acetylene flame, mechanical erosion overcame the chemical one. With increasing the flame angle, due to raising the surface temperature, chemical erosion overcame the mechanical one; so, most chemical destruction occurred at the flame angle of 90°. Also, the results of the erosion test showed that the total chemical and mechanical destruction at the angle of 60° was greater than that in other angles. Also, among the coatings tested, SiC/ZrB2- 20% wt. SiC/ZrB2 coatings had the best erosion resistance; so, the weight changes under the oxy-acetylene flame at the angles of 30° and 60°, respectively, were about −0.038%. and −0.355%; meanwhile, at the angle of 90°, it was about +4.3%.